Process of manufacturing condensation products from formaldehyde and phenol.



To-all whom it may concern:

UNITED STATES PATENTOFFJICE,

HANS STOCKHAUSEN, OF. CREFELD, AND REINHOLD GRUI-IL; OF vCHARL-O'JI'TIENIBURGr, GERMANY.

PROCESS OF MANUFACTURING CONDENSATION PRODUCTS FROM FORMALDEHYDE AND PHENOL.

Be it known that we, HANS STOCKIIAUSEN, manufacturer, and Doktor REINI-IOLD GRUHL, subjects of the German Emperor, residing, respectively, at Orefeld and at Charlottenburg, near Berlin, Germany, have invented a new and useful Process of Manufacturing Condensation Products from Formaldehyde and Phenol; and we do hereby declare the following to be a full, clear, and exact description of the same.

The'invention consists in heating formaldehyde and phenol with or without a condensation agent until the formation of a liquid intermediate product, and in then mixing this intermediate product with ferric chlorid, aluminum chlorid or other compounds of trivalent 'metal's whereby it'is converted into a plastic, moldable mass which requires to be heated for only a very short time in order to be converted into the non-meltable, insoluble and inodorous final state. It is preferable to interrupt the reaction between the formaldehyde and phenol by an admixture of cold water and thorough lixiviation with the same, as soon as a condensation product insoluble in water has been formed. The correct time for this can generally be recognized by, the previously clear liquid becoming turbid. If'no turbidity appears, it suffices to shake a test of the mass with cold water in order to see whether it is already insoluble in water.

. This interruption of the reaction has the advantage that the liquid intermediate product mixed with ferric chlorid and the like can be converted free from bubbles into the plastic intermediate product and into the solid infusible final product without having to employ a high pressure for preventing bubbles. The utility of the ferric chlorid consists in the following advantages: The converting of the intermediate condensation product into the insoluble and infusible final product by heating takes place in a less, while the products Patented Aug. 17, 1915.

Application filed April 1, 191a. Serial No. 758,254.

perature exactly under 100 0., because byv I the pressure of ferric chlorid the bubbles are avoided even if the temperature is raised .above 100 C. Finally, the products produced by means of ferric chlorid are odorknown way smell badly.

The invention may be carried into practice, for example, as follows: 100 phenol and 1 g. 40% formaldehyde %or their homologues or analogues) and an admixture of caustic soda lye are heated together. In the heat, a perfectly clear solution gradually forms in which the reaction which is beginning can be observed owing to the formation of heavy streaks which sink to the bottom. As the heat increases bubbles are gradually formed, and now the heat of reaction alone suffices for continuing the formati on of the condensation products. After some time the liquid begins to iridize and gradually to become turbid. The original added. The quantity thereof depends on the v desired degree of plasticity. The more ferric chlorid, the harderis the plastic mass and the shorter the duration of heating for conversion into the final state. The mixture is treated in a rolling mill or a kneading machine, when the further condensation connected with water being split off occurs. The water which is split off can then be removed purely mechanically, e. g. by kneading or rolling the plastic mass. When heated, the mass is converted without the em- I ployment of pressure into the infusible and ficient number of the same are superposed perature, water and oils. The mass can be one on' another according to the desired thickness of the final product, put under a press and heated. The temperature must exceed 100 C. but may not be so high that the fibers of the papers suffer. After cooling, the plates or slabs are hard,.no longer divisible into layers, and resist high temsawed, planed, filed, cut, drilled, polished, provided with screw-threads and so on. It can be made in any desired shape. The mass is an excellent insulator ofthe electric current, particularly when a thick not very porous paper is used. The plastlc intermediate product can also be mixed with caoutchouc and sulfur, as well as with, filling materials such as minerals, e. g. flakes of mica, powdered mica, powdered marble, orfibrous materials, 6. g. cellulose fibers, woolen, cotton and asbestos fibers, cotton, wool, paper, cork, or the like. I

7 An example showing more specifically the amounts of the materials usedmay be as follows: 100 grams of raw phenol of trade are treated in the described way with 100 grams of formaldehyde (40%) and 40- g. caustic soda lye (30%). The 1 liquid intermediate product so obtained is then thoroughly mixed with 80 grams of molten ferric chlorid. The mass is converted into a black plastic and kneadable mass; It is completely separated from the water produced hereby by kneading or rolling. After drying a very short heating-to 100 C. or more is suflicient to produce the infusible whiteyellow final product. The-plastic mass can be mixed with 3O grams of sulfur before heating it. 3'

The ferric chlorid mentioned in the above example and in theclaims can be substituted by its chemical equivalents z. e. aluminum chlorid or other compounds of trivalent metals. P

Having' thus described our invention, what we claimas new and-desire to secure by Letters Patent is 1. A process of manufacturing condensation products .from formaldehyde .and phenol, consisting in heating formaldehyde insoluble in water is formed, in washing the condensation product with cold water and mixing it with ferric chlorid until a plastic, moldable mass is formed, and in heating the said mass, whereby thefinal product is obtained. v

3. A process, of manufacturing condensation products from formaldehyde and phenol, consisting in heating formaldehyde with phenol until a liquid intermediate product is formed, in mixing this interinedi-. ate product with. ferric chlorid until a plastic, moldable mass is produced, in mixing said mass with caoutchouc and sulfur, and in then heating the mixture thus obtained.

4. A process of manufacturing condensation products from formaldehyde and phenol, consisting in heating formaldehyde with phenol until a condensation product insoluble in water is formed, in washing, said condensation product with cold water and mixing it with ferric chlorid until a plastic, moldable mass is obtained, in mixing said mass with caoutchouc and sulfur, and in heating the mixture thus obtained.

- 5. A process of manufacturing condensation products from formaldehyde and phenol, consisting in heating formaldehyde with phenol until a liquid intermediate product has formed, and in then mixing this intermediate product with ferric chlorid untila plastic, moldable mass is formed, in mixing said mass with filling substances, and in heating said mass, whereby the final product is obtained. 6. A process of manufacturing condensation products. from formaldehyde and phenol, consisting in heating formaldehyde with phenol until a condensation product insoluble in wtaer is formed, in washing the condensation product with cold water 'and mixing it with ferric chlorid until a plastic,

moldable mass is formed, in mixing said mass with filling substances, and in heating the said mass, whereby the final product-is obtained.

7. A process of manufacturing condensation products from formaldehyde and phenol, consisting in heating formaldeh de with phenol 'until a liquid intermediate product is formed, in mixing this intermediate product with ferric chlorid until a plastic, moldable mass is produced, in mixing .ture thus obtained.

8. A process of manufacturin condensation products from formaldehy ev and 'phe n01," consisting in heating 1 formaldehyde witli phenpl until a condensation product insoluble 1n water is formed, in washing vsaid condensation productwith cold water and mixing it with ferric chlorid until a I plastic, moldable mass is obtained, in mixing said mass with caoutchouc and sulfur time thus obtained.

In testimony whereof, wehave signed our 15 names to this specification in the presence of two SllbSCIlblIlg witnesses.

. HANS STOCKH USENZ DOKTOR REIN OLILGRUHL;

Witnesseshs tothe signature of Hans Stockhausen:

Enum KALnUson, HENRY QUADFLIEG.

v Witnesses as to the signature of Reinhold Gruhl: and filling meai'is,-and in heating-the mix- I Hnmnz HASPER, WOLDEMAR HAUPT. 

